Three-dimensional scouring article including metallic wires

ABSTRACT

The present application is spacer knit construction including a first surface, a second surface, and spacer pole filaments connecting the first and second surfaces. The spacer knit construction is comprised at least partially of metallic wires.

FIELD OF THE INVENTION

The present invention is related generally to the field of scouring articles. In particular, the present invention is a three-dimensional scouring article having metallic wires.

BACKGROUND

There are a number of various cleaning tools, including scouring pads and laminates, to suit different cleaning needs. A widely used type of tool is stainless steel scouring articles due to their aggressive cleaning action, easy availability, and low cost. However, there are certain limitations to using stainless steel in terms of durability, performance, and safety. In particular, stainless steel can lose its shape within a relatively short amount of time, flatten or break into pieces, leave deep scratches on the utensils, create sharp ends when broken, may not reach into corner due to lack of maneuverability, does not generate much foam during cleaning, and allows food particles to get trapped within the structure. While scouring pads can address many of the above concerns of stainless steel, they can fail to deliver as aggressive a scouring action as stainless steel. In addition, scouring pads designed to have aggressive scouring action can be costly to produce, have limited durability, can lose shape overtime, and experience a deterioration of performance over time.

There is therefore a need in the industry for a cleaning tool that can provide aggressive scouring action while maintaining shape and durability.

BRIEF DESCRIPTION OF THE DRAWINGS

This disclosure may be more completely understood in consideration of the following detailed description of various embodiments of the disclosure in connection with the accompanying drawings, in which:

FIG. 1A shows a perspective view of a first embodiment of the scouring article of the present invention.

FIG. 1B shows a cross-sectional view of the first embodiment of the scouring article of the present invention.

FIG. 2 shows a side view of a second embodiment of the scouring article of the present invention.

FIG. 3 shows a modelling example of a scouring article of the present invention.

While the above-identified figures set forth several embodiments of the disclosure, other embodiments are also contemplated, as noted in the description. In all cases, this disclosure presents the invention by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of the principles of the invention

SUMMARY

In one embodiment, the present application is spacer knit construction including a first surface, a second surface, and spacer pole filaments connecting the first and second surfaces. The spacer knit construction is comprised at least partially of metallic wires.

In another embodiment, the present invention is a scouring article including a three-dimensional spacer knit construction. The spacer knit construction includes a first surface, a second surface, and spacer pole filaments positioned between the first and second surfaces. The spacer knit construction includes metallic wires.

DETAILED DESCRIPTION

The present invention is a scouring article including a three-dimensional spacer knit construction having a first surface, a second surface, and a spacer pole filament between the first and second surfaces. Metallic wire, such as flat stainless steel wire, is incorporated into the three-dimensional spacer knit construction. The design results in a combination of the aggressive scouring action of metal while also providing the benefits of a scrub pad, such as durability and the ability to foam and lather. By including the flat metallic wire in the three-dimensional spacer knit construction, the scouring article has excellent compression elasticity. The scouring article is breathable, with air permeability due to the open structure. The design also provides cushioning such that it is soft and gentle on the user and good bending performance, allowing maneuverability to reach hard to reach areas. The three-dimensional spacer knit construction also allows for more even pressure distribution, resulting in less wear and tear and leading to increased durability. The structure of the scouring article also makes the overall product lightweight and offers various surface design capabilities. The scouring article of the present invention also has excellent dimensional stability, with minimal to on shrinkage or loss of shape.

The scouring article of the present invention is a three-dimensional knitted fabric made of two separate knitted substrates that are joined together or kept apart by spacer pole filaments. FIGS. 1A and 1B show a perspective view and a cross-sectional view, respectively, of a first embodiment of a scouring article of the present invention. FIG. 2 shows a side view of a second embodiment of a scouring article of the present invention. The three-dimensional spacer knit construction generally includes a first surface (10), a second surface (12), and a spacer pole filament (14) connecting the first and second surfaces in a sandwich-like configuration. The first and second surfaces (10, 12) function as working layers that contact a surface to be cleaned. The first surface (10), second surface (12), and spacer pole filaments (14) of the three-dimensional spacer knit construction can be formed from similar or different materials and can include metal, polymers, or a combination thereof.

The spacer pole filaments (14) offer flexibility to the first and second surfaces (10, 12) and the overall spacer knit construction to meet end use requirements. For example, each of the first and second surfaces (10, 12) can be hydrophilic or hydroscopic. In one embodiment, the first and second surfaces (10, 12) are different in nature. In another embodiment, the first and second surfaces (10, 12) are similar in nature. The spacer pole filaments (14) can be mono or multifilament. This makes it possible to design the appearance of the first and second surfaces (10, 12), which may require separate performance and aesthetic qualities. The possibility of designing two distinct working surfaces along with the variability of the connecting spacer pole filament materials and thicknesses allows for a number of potential application solutions.

The spacer knit construction is made at least partially of metallic wires. The metallic wires offer abrasive action while having enough flexibility to sustain the knitting operation to form the spacer knit construction. In one embodiment, the metallic wires are flat. Use of flat metallic wires as an abrasive substrate either on one or both of the first and second surfaces (10, 12) gives the spacer knit construction scouring action. The scouring power of the flat metallic wires can be tuned by varying the type, width, and thickness of the flat metallic wires. The flat metallic wires can also have different scouring power. For example, the flat metallic wire can have mild scouring power (i.e, grade AISI 304 and below) or strong scouring power (i.e., grade AISI 410/AISI 430 and above). Examples of suitable metallic wires include, but are not limited to, stainless steel, aluminum, copper, brass, and nickel. In one embodiment, different metallic wires can be used to generate different patterns, color combinations, designs, and effects on the first and second surfaces of the spacer knit construction.

In one embodiment, if the spacer knit construction with metallic wire interlacement is to be used in a steel mesh sponge bar (as shown in FIG. 2 ), metallic wire interlacement on only one surface of the spacer knit construction is recommended.

Other materials can also be used in combination with the metallic wire to make up the spacer knit construction such as non-metallic fibers and yarns. In one embodiment, a flat slit film yarn is used in combination with the metallic wire. For example, yarns used for manufacturing the spacer knit construction material can be synthetic, regenerated or spun, and/or made from natural or man-made fibers. Examples of natural fibers include, but are not limited to, cotton, jute, coir, silk, and hemp. Examples of regenerated fibers include, but are not limited to, viscose, modal, and TENCEL. Examples of synthetic fibers include, but are not limited to, polyester, polyamide, polypropylene, nylon, acrylic, acetate, spandex, ORLON, KEVLAR, LYCRA and latex. Any combination of the above-mentioned fibers can be chosen depending on the end use application and manufacturing process feasibility. In one embodiment, the slit film yarn may include, but is not limited to, polyester, polyamide, polyethylene, HDPE, PET, polypropylene, or any combination thereof. The monofilaments can offer other variations by virtue of diameter, cross-section, color, tensile strength etc. In one embodiment, the slit film yarns have a width about 0.3 to about 5 mm and a thickness of about 50 microns to about 500 microns.

The working surfaces and spacer pole filaments of the scouring article can be formed from any combination of metallic wires and slit film yarns. The metallic wires and slit film yarns can include any variety of cross-sections, depending on the desired end use. For example, as mentioned above, having a flat cross-section can increase the scouring capability of the metallic wires. However, the metallic wires and slit film yarns can have other cross-sections without departing from the intended scope of the present invention. In one embodiment, the structure of the spacer knit construction is a dual action scouring tool having only slit film yarn on one surface (for non-scratch cleaning action) and only metallic wire on the other surface (for deep scouring action for cleaning tough stains). In another embodiment, the spacer knit construction has one surface without any abrasive elements in it and the other surface with either only slit film yarn or metallic wire. In another embodiment, the spacer knit construction uses only mild stainless steel grade flat wire on one surface of and tough stainless steel grade flat wire on the other surface for variation in scouring power.

The spacer knit construction may also include other additives for particular purposes. For example, the spacer knit construction may include an antimicrobial agent or biocide treatment to resist bacteria. Examples of suitable biocides include, but are not limited to, benzalkonium chloride, sodium dichloroisocyanurate, benzisothiazolinone and chlorhexidine. Other additives include, but are not limited to, surfactants, abrasive particles, cleaning agents, coupling agents, plasticizers, adhesion promoters, grinding aids, wetting agents, dispersing agents, light stabilizers, antioxidants, anti-static agents, foaming agents, anti-foaming agents, suspending agents, coloring agents, dyes, pigments, and fragrances.

In one embodiment, the materials making up the spacer knit construction may be treated to increase the abrasive performance of the scouring article. For example, the spacer knit construction material may be coated or textured. The slit film yarn can also be plain or have a metallized color coated form to give an essence of a particular material, such as copper, brass, nickel, silver or gold flat wire. In one embodiment, the spacer knit construction material is made from recyclable materials. In another embodiment, the spacer knit construction material is substantially free of latex.

In one embodiment, the spacer knit construction has a thickness of between about 2 and about 40 mm. In one embodiment, the spacer knit construction has a final grammage of between about 100 and about 800 grams/square meter. In one embodiment, the spacer knit construction has a density of between about 25 and about 75 Kg/cubic meter. By varying these parameters, the openness (density), stiffness, and compression of the spacer can be designed to meet particular end use requirements.

The three-dimensional spacer knit construction is similar to a sandwich structure having two separate layers joined together by spacer pole filaments of varying rigidity. The first and second surfaces (10, 12) of the scouring article are knitted separately at the same time they are connected by monofilament yarns making up the spacer pole filament. In one embodiment, the surfaces of the spacer knit construction are made by interlacing a flat slit film yarn, such as polyester, nylon or polypropylene, together with the flat metallic wire. The flat slit film yarn supports the flat metallic wire to form an abrasive working surface.

The knitting structure of the slit film yarn and metallic wire can be varied to get the desired scouring action in the form of a plain knit. Loop structure, pile structure and combinations thereof are also feasible. Varying the knit pattern, design, structure, and density of the spacer knit construction materials can give the surfaces of the spacer knit different properties. For example, using different metal wires and slit film yarns can generate different patterns, color combination, designs, and scouring effects for the surfaces of the spacer knit construction. In addition, by varying the pattern size, the coverage and scouring power can also be varied. In one embodiment, the slit film yarn and metallic wire are knitted in a pattern on one or both surfaces of the spacer knit construction. The pattern can be in form of design or logo or combination thereof. FIG. 3 shows a modelling example of a spacer knit construction of the present invention in which the some of the darker threads are metallic wires (35, 37) and the lighter threads are slit film yarn (39).

The spacer knit construction can be made using a variety of methods. The most common techniques used for manufacturing is warp knitting or weft knitting. For the present invention, various modifications can be made to account for the metallic wires. For example, the knitting needle and components that guide and come in contact with the metallic wires can be coated in ceramic to avoid wear and tear. The speed and cam design can be altered so that there is minimum friction and heat generated during manufacturing. The slit film yarn and metallic wires can also be lubricated with oil, sizing agent, or wax to prevent disintegration during the manufacturing process.

The three-dimensional spacer knit construction of the present invention can perform aggressively while being offered in the form of a scouring pad having any variety of shapes. It is therefore flexible, compressible, and offers a cushioning effect, providing a better user experience. The spacer knit construction has a dimensionally stable structure and does not loosen or disintegrate during use. Because the metallic wire is knitted along with slit film yarn, the spacer knit construction has minimal breakage and is safe to use. The scouring product has an open structure, with the result that food particles do not get trapped within the article and wash off easily. The open structure also allows the article to dry faster and to generate foam, reducing the consumption of any cleaner that might be used with the scouring article. As the aggressiveness of the working surfaces can be tuned, the spacer knit construction can be designed not to leave deep scratches on any surface to be cleaned. Lastly, the three-dimensional spacer knit construction can be offered as a multipurpose tool, giving different levels of abrasive action for different cleaning needs in a single tool.

In one embodiment, the scouring article includes a handle or grip attached to the spacer knit construction for better handling of the spacer knit construction. The grip may be anywhere from hard and rigid to soft and flexible, depending on the design of the particular tool, e.g., a tool with a harder more rigid grip may require less work to use as compared to a tool with a soft and flexible grip. The grip can be formed of any material known to those of skill in the art. For example, the grip may include porous or nonporous materials. Exemplary porous materials include, but are not limited to, natural and synthetic foams, sponges, and polymers. Porous materials may have an open or closed cell structure and/or small or large pores. Exemplary nonporous materials include, but are not limited to, natural and synthetic polymers.

Any polymer known to be used for grips may be used, including porous rubber, silicon, melamine or post treated impregnated foams, foamed polyester, cellulose materials, low and high density polyethers and polyesters, neoprene, natural rubber, styrene-butadiene rubbers, ethylene-propylene rubbers, butyl rubbers, butadiene rubbers, nitrile rubbers, epichlorohydrin-based polymers, acrylonitrile butadiene styrene, high impact polystyrene, polycarbonate, polystyrenes, polyolefins such as polyethylene and polypropylene, ethylene vinyl acetate, EMA, metallocene resin, polyurethane, polyvinylchloride, flame retardant polymers, blends of any of the above, and the like.

The grip can be attached to the spacer knit construction by any method known to those of skill in the art, including, but not limited to, mechanical or adhesive means.

The three-dimensional spacer knit construction of the present invention can be used in a variety of applications. Examples include, but are not limited to, scouring pads, floor pads, polishing pads, abrasive pads for grinding, car detailing etc.

Various modifications and alterations to this disclosure will become apparent to those skilled in the art without departing from the scope and spirit of this disclosure. It should be understood that this disclosure is not intended to be unduly limited by the illustrative embodiments and examples set forth herein and that such examples and embodiments are presented by way of example only with the scope of the disclosure intended to be limited only by the claims set forth herein as follows. All references cited in this disclosure are herein incorporated by reference in their entirety. 

What is claimed is:
 1. A spacer knit construction comprising: a first surface; a second surface; and spacer pole filaments connecting the first and second surfaces, wherein the spacer knit construction is comprised at least partially of metallic wires.
 2. The spacer knit construction of claim 1, wherein the spacer knit construction is comprised at least partially of slit film yarn.
 3. The spacer knit construction of claim 2, wherein the slit film yarn is selected from the group consisting of polyester, polyamide, polyethylene, HDPE, PET, polypropylene, and combinations thereof.
 4. The spacer knit construction of claim 1, wherein the metallic wires are selected from the group consisting of stainless steel, aluminum, copper, brass, nickel, and combinations thereof.
 5. The spacer knit construction of claim 1, wherein the metallic wires have a flat cross-section.
 6. The spacer knit construction of claim 1, wherein the first surface and the second surface have different scouring properties.
 7. The spacer knit construction of claim 1, wherein the metallic wire is interlaced into at least one of the first and second surfaces.
 8. A scouring article comprising: a three-dimensional spacer knit construction, wherein the spacer knit construction comprises: a first surface; a second surface; and spacer pole filaments positioned between the first and second surfaces, wherein the spacer knit construction comprises metallic wires.
 9. The scouring article of claim 8, wherein the spacer knit construction further comprises slit film yarn.
 10. The scouring article of claim 9, wherein the slit film yarn is selected from the group consisting of polyester, polyamide, polyethylene, HDPE, PET, polypropylene, and combinations thereof.
 11. The scouring article of claim 8, wherein the metallic wires are selected from the group consisting of stainless steel, aluminum, copper, brass, nickel, and combinations thereof.
 12. scouring article of claim 8, wherein the metallic wires have a flat cross-section.
 13. The scouring article of claim 8, wherein the first surface and the second surface have different scouring properties.
 14. The scouring article of claim 8, further comprising a handle attached to the spacer knit construction. 